Comparing Traditional and Programmatical safety systems

Programmatical safety and traditional hardwired safety are two different approaches to ensuring safety in control systems. Each approach has its own advantages and disadvantages, and the choice between them depends on the specific requirements and constraints of the system in question. Let’s compare these two approaches:

Programmatical Safety

Programmatical safety utilizes safety PLCs along with robust ethernet-based protocols to ensure functional safety systems meet safety standards. Many manufacturers have offerings under different names, here are a few common ones.

Benefits of Programmatical Safety

• Flexibility: Programmatical safety relies on software-based safety mechanisms. This means that safety features can be reconfigured or updated through software changes, providing flexibility in adapting to evolving safety requirements or system changes.
• Cost-Efficiency: On large systems, it can be more cost-effective in terms of hardware, as it doesn’t require as many physical components and wiring as hardwired safety systems. 
• Integration: Programmatical safety can be seamlessly integrated into the control system’s software, making it easier to implement diagnostics to manage and monitor safety functions alongside other control functions.
• Complexity: It can handle complex safety logic and interlocks efficiently, making it suitable for systems with intricate safety requirements.
• Diagnosis and Maintenance: Programmatical safety systems can offer diagnostic capabilities, allowing for easier identification of faults and quicker maintenance.
• Traceability: Features such as safety signatures, safety pulse testing, and current monitoring can ensure failsafe systems are tamper-proof. Control Engineers and EHS departments can prevent and track changes.

Drawbacks of Programmatical Safety

• Cost-Efficiency: On very small systems with simple safety requirements the safety processors and hardware can be more expensive than a simple safety circuit.
• Hardware Selection: Requiring a certain safety protocol can limit hardware options because not all devices, such as variable frequency drives, support all safety protocols.

Hardwired Safety

Hardwired safety systems are comprised solely of electro-mechanical components such as relays, E-stops, and switches. Redundant components ensure fail-safe operation.

Benefits of Traditional Safety

• Simplicity: On very small systems with simple safety requirements traditional safety systems are easy to validate and troubleshoot.
• No Programming Knowledge: Programmatical safety systems do no require any programming knowledge since there is no safety PLC.

Drawbacks of Traditional Safety

• Lack of Flexibility: Changing safety configurations or adding new safety features can be costly and time-consuming, requiring rewiring and hardware modifications.
• Complexity: Handling complex interlocks and safety logic can be cumbersome and may involve a large number of physical components, making the system less scalable and harder to maintain.
• Integration Challenges: Integrating hardwired safety with other control functions can be more challenging compared to programmatical safety.

The barrier to entry on programmatical safety systems has become very low making programmatical safety the better choice for most new systems. However, traditional safety systems are still a good option for many small or simple systems. The choice between these approaches ultimately depends on the specific safety requirements and constraints of the system being designed. Maskine can help make this determination, contact us for further information.